Atomization system for electronic cigarette

ABSTRACT

An atomization system for an electronic cigarette comprises a liquid ejection unit, which comprises a housing having a first end and a second end and a vaporization chamber; a vaporization element in the vaporization chamber; and an ejection plate proximal to the first end and comprising a plurality of micro-openings. An electronic cigarette comprises the atomization system disclosed herein. The atomization system may further comprise a liquid supply unit coupled with the ejection unit.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of International Application No. PCT/CN2018/087325, filed May 17, 2018, which is herein incorporated by reference in its entirety.

TECHNICAL FIELD

The field of the invention is an atomization system for electronic cigarettes.

BACKGROUND OF THE INVENTION

An electronic smoking device, such as an electronic cigarette (e-cig or e-cigarette), electronic cigar, personal vaporizer (PV) or electronic nicotine delivery system (ENDS) is a battery-powered vaporizer which creates an aerosol or vapor. In general, these devices have a heating element that atomizes a liquid solution known as e-liquid. There remains a need for an improved atomization system.

SUMMARY OF THE INVENTION

Provided herein is a novel atomization system for an electronic cigarette comprising a liquid ejection unit (hereinafter the “ejection unit”), an electronic cigarette comprising the same, and a novel atomization method for vaporizing an e-liquid in an electronic cigarette using the atomization system. The atomization system may further comprise a liquid supply unit coupled with the ejection unit.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a section view of an embodiment of the ejection unit.

FIG. 1B is a section view of another embodiment of the ejection unit.

FIG. 1C is a section view of another embodiment of the ejection unit.

FIG. 2 is a front view of an ejection plate of an embodiment of the ejection unit.

FIG. 3A illustrates an embodiment of the ejection unit filled with e-liquid.

FIG. 3B illustrates an ejection of the ejection unit of FIG. 3A.

FIG. 3C illustrates an e-liquid refill of the ejection unit after the ejection of FIG. 3B.

FIG. 4 is a section view of an embodiment of an atomization system comprising the ejection unit and a liquid supply unit.

FIG. 5A is a section view of an embodiment of an electronic cigarette comprising an atomization system comprising the ejection unit and the liquid supply unit.

FIG. 5B is a section view of another embodiment of an electronic cigarette comprising an atomization system comprising the ejection unit and the liquid supply unit.

FIG. 6 is a section view of another embodiment of an electronic cigarette which comprises an atomization system without the liquid supply unit.

DETAILED DESCRIPTION

An atomization system includes an ejection unit having a vaporization chamber defined by a housing with a first end and a second end, and a vaporization element in the housing. The vaporization chamber is filled with an e-liquid when in use. The first end comprises an ejection plate comprising multiple micro-openings. The sizes of the micro-openings are so small that the liquid surface tension around these micro-openings can prevent e-liquid from leaking when the vaporization element is not activated. When the heating element is activated, a portion of the e-liquid in the vaporization chamber is vaporized. The vaporized portion of the e-liquid expands due to the liquid to gas phase change and forces the unvaporized e-liquid through the micro-openings to form an aerosol. The aerosol may be suitable for inhalation without further atomization processes (e.g., by heat, vibration, ultrasound, and microwave). The particle size distribution of the aerosol may be adjusted and controlled by the sizes and shapes of the micro-openings, as well as the distances between the adjacent micro-openings.

In order to fully understand the manner in which the above-recited details and other advantages and objects according to the invention are obtained, a more detailed description of the invention will be rendered by reference to specific embodiments thereof. Other features and advantages of the invention will become apparent from the following detailed description. Although the invention has been described with reference to various embodiments and specific examples, it will be readily appreciated by those skilled in the art that many modifications and adaptations of the invention are possible without deviating from the spirit and scope of the invention. Thus, it is to be clearly understood that this description is made only by way of example and not as a limitation on the scope of the invention. For example, the elements of one embodiment can be combined with other embodiments in addition to or in lieu of the elements of other embodiments.

I. Ejection Unit

A section view of an embodiment of the ejection unit 1 is provided in FIGS. 1A and 1B. The ejection unit 1 comprises a vaporization chamber 10 defined by a housing 11 having a first end 12 and a second end 13; an ejection plate 14 proximal to (FIG. 1A) or at (FIG. 1B) the first end 12, wherein the ejection plate 14 comprises multiple micro-openings 15; an opening 16 proximal to or at the second end 13, which is sealed by a one-way valve 17 that can open inwards of the vaporization chamber 10; and a vaporization element 18 in the vaporization chamber 10. The vaporization element 18 may be positioned proximal to the opening 16.

Alternatively, as shown in FIG. 1C, the second end 13 of the ejection unit 1 may be a closed end. The vaporization element 18 may be proximal to the closed second end 13. The ejection plate 14 comprises multiple micro-openings 15.

The housing 11 may have any shape suitable, e.g., a tubular, a cubic, triangular, hexangular, and polyangular. The housing 11 may be made of one or more materials (e.g., steel) having a Rockwell C scale of hardness (HRC) of about 50 to about 75, about 55 to about 70, about 58 to 65, or about 60.

The ejection plate 14 may be positioned inside of the vaporization chamber 10 (FIG. 1A). Alternatively, the ejection plate 14 may be positioned at the first end 12 of the housing 11 (FIG. 1B). The ejection plate 14 may be separable from the housing 11. The ejection end 12 may have any shape suitable, e.g., circular, rectangular, square, triangular, diamond, or any polygonal shapes. A thickness of the ejection plate 14 may be about 50 μm to about 5 mm, about 100 μm to about 3 mm, about 500 μm to about 2 mm, about 750 μm to about 1.5 mm, or about 1 mm. The ejection plate 14 may comprise one or more materials (e.g., steel) having a Rockwell C scale of hardness (HRC) of about 50 to about 75, about 55 to about 70, about 58 to 65, or about 60.

The ejection plate 14 may comprise micro-openings 15 having a uniform size (FIG. 2) or varied sizes. The micro-openings 15 may have a size of about 0.5 μm² to about 20 μm², or about 0.785 μm² to about 19.625 pm². The micro-openings 15 may have a uniform shape or varied shapes including, without limitation, circular, rectangular, square, triangular or any polygonal shapes. The micro-openings 15 may have the same or varied distances between adjacent micro-openings. The shortest distances between adjacent micro-openings may be at least 10 μm, about 10 μm to about 100 μm, about 10 μm to about 75 μm, about 10 μm to about 50 μm, about 10 μm to about 30 μm, or about 10 μm to about 20 μm. Each ejection plate 14 may have 50 to about 1,000, about 100 to about 800, about 200 to about 500, or about 300 to about 400 micro-openings 15. The micro-openings 15 may be arranged into any desired pattern provided that the shortest distance between any adjacent micro-openings is at least 10 μm, about 10 μm to about 100 μm, about 10 μm to about 75 μm, about 10 μm to about 50 μm, about 10 μm to about 30 μm, or about 10 μm to about 20 μm.

The one-way valve 17 can be opened inwards of the housing 11 to allow refill of e-liquid into the vaporization chamber 10. The one-way valve 17 will block the opening 16 by the liquid pressure once the vaporization chamber 10 is filled with e-liquid.

The vaporization element 18 can be any device that can vaporize e-liquid in close proximity. For example, the vaporization element 18 can be a heating element (e.g., heating coil (FIGS. 1A-1B)), microwave unit, and/or ultrasound unit.

FIG. 3A shows a section view of the ejection unit 1 of FIG. 1 filled with an e-liquid 20 before activation of the vaporization element 18. The opening 16 may be coupled with a liquid-supply unit (not shown) that can fill the housing 11 with e-liquid through the one-way valve 17. The vaporization element 18 may be positioned closer to the opening 16 than to the first end 12. Thus, when the vaporization element 18 is activated, as shown in FIG. 3B, the e-liquid proximal to the opening 16 will be vaporized into e-liquid vapor 21 that expands and forces the heated but not vaporized e-liquid 22 towards the ejection plate 14 and through the micro-openings 15 to eject aerosol 23. After the ejection, as shown in FIG. 3C, a vacuum is created in the vaporization chamber 10 and activates the one-way valve 17 to refill the vaporization chamber 10 with e-liquid 20 for the next ejection.

The e-liquid may comprise one or more volatile solvents. Examples of the suitable volatile solvents include, without limitation, cyclohexane, and alcohol (e.g., ethanol). The one or more volatile solvents together constitute more than about 40%, more than about 50%, or more than about 60% of the total volume of the e-liquid.

The ejection unit 1 may further comprise an opening on the housing 11 or the second end 13 for e-liquid refill. The opening may further comprise an one-way valve or a seal to prevent leaking.

II. Atomization System

Provided herein is also an atomization system comprising the ejection unit. The atomization system may further comprise a liquid-supply unit coupled to the opening of the second end of the ejection unit to supply e-liquid for ejection.

FIG. 4 shows a section view of an embodiment of the atomization system 40 comprising an ejection unit 1 and a liquid-supply unit 50. The liquid-supply unit 50 comprises a liquid-storage chamber 55 defined by a housing 51 with a third open end 52 and a fourth closed end 53, and a liquid transfer element 54 in the liquid-storage chamber 55. The liquid-storage chamber 55 may contain e-liquid. The liquid transfer element 54 is coupled with the one-way valve 17 to feed e-liquid from the liquid-storage chamber 55 into the vaporization chamber 10 of the ejection unit 1. The liquid transfer element 54 comprise a housing 56 extending from the one-way valve 17 to close to the bottom of the liquid supply unit 50. E-liquid is supplied to the ejection unit 1 through the inner chamber of the housing 56.

The housing 11 of the ejection unit 1 may be separable from the housing 51 of the liquid-supply unit 50. Alternatively, the housing 11 and the housing 51 may be integrated as one.

The liquid-supply unit 50 may be refilled through the third open end 52. Optionally, the liquid-supply unit 50 further comprises another opening 57 on the housing 51 or the second end 53 for e-liquid refill. The opening 57 may further comprise a one-way valve or a seal to prevent leaking.

III. Electronic Cigarette

Provided herein are also embodiments of an electronic cigarette comprising the atomization system comprising an ejection unit, an inhalation unit in airflow communication with the micro-openings of the ejection unit, and a battery unit electrically coupled to the vaporization element.

FIG. 5A illustrates an embodiment of the electronic cigarette 100 comprising an inhalation unit 60, an atomization system 40 that comprises an ejection unit 1 and a liquid-supply unit 50, and a battery unit 70. The inhalation unit 60 is in airflow communication with the micro-openings 15 of the ejection unit 1. The inhalation unit 1 may comprise a mouthpiece 61 optionally comprising one or more filter materials.

The battery unit 70 comprises a battery 72 and optionally a control circuit 73 that can activate the vaporization element 18. The vaporization element 18 may be activated by a sensor 74 that can sense the inhalation of a user and coupled to the control circuit 73, and/or by a switch 75 controlled directly by the user. Optionally the battery unit 70 further comprises an outer housing 71 that houses the battery 73, optionally the control circuit 73 and one or more conductive elements that electrically couple the vaporization element 18 and the battery unit 70. Alternatively, the housing 11 of the ejection unit 1 and/or the housing 51 of the liquid-supply unit 50 may comprise one or more conductive elements that electrically couple the vaporization element 18 and the battery unit 70 (FIG. 5B).

FIG. 6 shows another embodiment of the electronic cigarette 100 comprising the atomization system 40 that comprises the ejection unit 1 without the liquid-supply unit, an inhalation unit 60 in airflow communication with the micro-opening 15 of the ejection unit 1, and a battery unit 70 electrically coupled to the vaporization element 18. The second end 13 of the ejection unit 1 is a closed end. The inhalation unit 1 may comprise a mouthpiece 61 optionally comprising one or more filter materials. The battery unit 70 comprises a battery and optionally a control circuit that can activate the vaporization element 18. The vaporization element 18 may be activated by a sensor that can sense the inhalation of a user, and/or by a switch controlled directly by the user. Optionally the housing 11 of the ejection unit 1 comprises one or more conductive elements that electrically couple the vaporization element 18 and the battery unit 70.

IV. Atomization Method

Provided herein are also embodiments of an atomization method for an electronic cigarette comprising:

-   -   a) vaporizing a portion of an e-liquid in a vaporization chamber         by a vaporization element proximal to one end of the         vaporization chamber; and     -   b) the e-liquid vapor obtained from step a) expands and forces         the un-vaporized e-liquid in the vaporization chamber to eject         out of multiple micro-openings at the other end of the         vaporization chamber; wherein:

the aerosol obtained from the ejection of step b) has a particle size of about 0.5 μm to about 10 μm, about 1 μm to about 5 μm, or about 2 to about 3 μm as measured by mass median diameter (MMD).

The viscosity of the liquid, the ejection force, and the characteristics of the micro-openings may be adjusted to obtain a desired particle size.

A method for atomization of a liquid to create an aerosol for inhalation may also comprises:

-   -   providing an e-liquid in a vaporization chamber;     -   pressurizing the vaporization chamber; and     -   with the pressurizing forcing a portion of the liquid through a         plurality of micro-openings at a first end of the vaporization         chamber, with the movement of liquid through the micro-openings         dividing the liquid into particles of liquid forming an aerosol.

The method may further comprise pressurizing the vaporization chamber by heating liquid in the vaporization chamber.

The method may further comprise maintaining a volume of bulk liquid against the micro-openings in the vaporization chamber so that only bulk liquid passes through the micro-openings.

Thus, novel devices and methods have been shown and described. Various modifications and substitutions may of course be made without departing from the spirit and scope of the invention. The invention, therefore, should not be limited, except to the following claims and their equivalents. 

1. An electronic smoking device, comprising: a vaporization chamber in a housing; a vaporization element inside of the vaporization chamber; and an ejection plate at a first end of the vaporization chamber, the ejection plate having a plurality of micro-openings.
 2. (canceled)
 3. The electronic smoking device, claim 1 wherein each micro-opening has an area of 0.5 μm² to 20 μm².
 4. (canceled)
 5. (canceled)
 6. The electronic smoking device of claim 1 wherein the vaporization element is at a second end of the vaporization chamber.
 7. The electronic smoking device of claim 1 wherein the vaporization element comprises a heating element in the vaporization chamber.
 8. (canceled)
 9. (canceled)
 10. (canceled)
 11. The electronic smoking device of claim 6 wherein the second end of the vaporization chamber has a one-way which prevents flow of liquid out of the vaporization chamber.
 12. The electronic smoking device of claim 1 further comprising a liquid-supply unit having a liquid-storage chamber; and a liquid transfer element in the liquid-storage chamber, the liquid transfer element comprising a porous material; and the liquid transfer element extending to the vaporization chamber.
 13. (canceled)
 14. The electronic smoking device of claim 7 further comprising a liquid in the vaporization chamber and a battery electrically coupled to the heating element. 15-20. (canceled)
 21. The electronic smoking device of claim 14 wherein the heating element operates to pressurize the liquid in the vaporization chamber, forcing the liquid through the micro-openings to form an aerosol.
 22. An electronic smoking device comprising: a vaporization chamber in a housing, the vaporization chamber containing a liquid; a heating element in contact with the liquid in the vaporization chamber; an ejection plate at an end of the vaporization chamber, the ejection plate having a plurality of micro-openings; wherein the heating element operates to pressurize the liquid in the vaporization chamber, forcing the liquid through the micro-openings to form an aerosol.
 23. The electronic smoking device of claim 22 wherein substantially each of the micro-openings has an area of 0.5 μm² to 20 μm².
 24. The electronic smoking device of claim 22 wherein the ejection plate is at an end of the housing.
 25. The electronic smoking device of claim 22 further including a liquid transfer element comprising a porous material, the liquid transfer element extending from a liquid storage chamber to the vaporization chamber.
 26. The electronic smoking device of claim 24 further including a one-way valve at the vaporization chamber which allows liquid in the liquid storage chamber to flow in only one direction and into the vaporization chamber.
 27. The electronic smoking device of claim 22 wherein the vaporization chamber is defined by the housing and the vaporization chamber has a fixed volume.
 28. The electronic smoking device of claim 27 wherein the vaporization chamber is filled entirely with the liquid.
 29. A method for creating an aerosol for inhalation, comprising: providing a liquid in a vaporization chamber; heating the liquid to increase the pressure in the vaporization chamber; and the increase in pressure forcing a portion of the liquid through a plurality of micro-openings at a first end of the vaporization chamber, with the movement of liquid through the micro-openings dividing the liquid into particles of liquid forming an aerosol.
 30. The method of claim 29 further comprising pressurizing the vaporization chamber by heating liquid in the vaporization chamber.
 31. The method of claim 29 further comprising maintaining a volume of bulk liquid against the micro-openings in the vaporization chamber so that only bulk liquid passes through the micro-openings. 